Footwear Insole

ABSTRACT

A layered construction for a footwear insole connect an intermediate layer between a bottom layer and a top layer. A sealed passage for airflow is created between a plurality of three-dimensional pockets (connected on the top layer), a plurality of apertures (traversing through the intermediate layer), and a reservoir (positioned interior to the bottom layer). The three-dimensional pockets are deformable beneath the weight of a person&#39;s foot, which causes air to flow through conduits of the top layer, the apertures of the intermediate layer, and into the reservoir. When a person lifts their foot the three-dimensional pockets return to their normal shape, with air circulating back into the three-dimensional pockets from the reservoirs. The bottom layer can also be contoured to provide better support for a person&#39;s foot, matching a concave portion with the foot&#39;s longitudinal arches and a pair of wings with the transverse arch.

The current application is a continuation in part of U.S. patent application Ser. No. 13/602,290 filed on Sep. 3, 2012.

FIELD OF THE INVENTION

The present invention relates generally to an insole which has portions that uses a sealed air flow system to deform to better cushion a person's steps, as well as generate airflow within the insole.

BACKGROUND OF THE INVENTION

Safety footwear is classified as personal protective equipment, produced in different types and forms (shoes, boots, etc.) according to the intended user thereof, and protects workers' feet from various type of risk such as shocks, collisions, impact, thermal and chemical burns, puncturing and crushing, cuts and abrasions, heat, flames, and cold.

Safety footwear is provided with a protective toecap, to protect the feet in the event of material falling on the foot, and a puncture-resistant sole, consisting of a steel plate which protects the foot from sharp materials which could penetrate the sole such as nails, sharp-edge blades, or other hazards.

Safety footwear is furthermore provided with a nonslip rubber outsole, which also protects against the risk of electrocution, as well as a heat insulating insole.

All of this provides the wearer considerable protection, but very little comfort or support.

Safety footwear, and in particular the soles and insoles thereof, do not have comfort as an integral part of their construction. This causes numerous aches, pains, and injuries for individuals that are required to wear safety footwear for eight hours or more a day as a condition of their employment.

The present invention addresses that need for comfort and support in safety footwear, with a unique constructed insole pad to be inserted into the footwear. The present invention uses a layered construction, with an airflow system being incorporated into the compacted and layered construction. Three-dimensional pockets on a top layer deform to better support a person's feet, with air flowing through an intermediate layer into a reservoir of a bottom layer. The airflow system is enclosed and allows air to circulate between the three-dimensional pockets and reservoir as a person walks or otherwise shifts their weight. The present invention provides remains soft and comfortable under a person's foot, even when used for extended periods of time. The present invention provides substantial enhanced comfort, massaging a person's foot with every movement.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view showing three layers and air flow pathways of the present invention.

FIG. 2 is a top plan view of a top layer of the present invention.

FIG. 3 is a perspective view of the top layer of the present invention.

FIG. 4 is a top plan view of an intermediate layer of the present invention.

FIG. 5 is a top plan view of a bottom layer of the present invention.

FIG. 6 is a perspective view showing a transverse arch of a person's foot which is ergonomically supported by a first wing and a second wing.

FIG. 7 is a side view showing longitudinal arches of a foot which are ergonomically supported by a concave portion of the present invention.

FIG. 8 is a top plan view of the bottom layer showing how the present invention may be cut to fit different foot sizes.

DETAIL DESCRIPTIONS OF THE INVENTION

All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

The present invention is an improved insole for footwear, providing ergonomic support and cushioning through a layered construction and aerodynamics. The aerodynamics aspect is enabled by air (a natural organic compound element). It is noted that the term air preferably refers to Earth's atmosphere, which is primarily nitrogen and oxygen. The present invention comprises a top layer 1, a bottom layer 2, and an intermediate layer 3 which are combined to form the improved insole. Ergonomic support is provided by means of a airflow system which comprises a plurality of three-dimensional pockets 4, a plurality of apertures 5, and a reservoir 21; these components are connected in a method that allows for pressure differences to causes pressurized air to move and circulate through the three-dimensional pockets 4, apertures 5, and reservoir 21. The present invention is illustrated wholly and in part via the illustrations shown in FIG. 1-FIG. 7.

The top layer, bottom layer 2, and intermediate layer 3 form the core body of the present invention, with the layers being connected to each other to form a unitary core body as illustrated in FIG. 1. The intermediate layer 3 is between the top layer 1 and the bottom layer 2; the intermediate layer 3 is also adjacently connected to both the top layer 1 and the bottom layer 2. It is noted that the layers can be connected to each other by a variety of methods. For example, in one embodiment, a compound element (e.g. an adhesive material such as glue) is applied between the top layer 1 and the intermediate layer 3, as well as between the intermediate layer 3 and the bottom layer 2. This adhesive material causes the layers to bond to each other, the layers additionally being compressed with heat, thus forming the desired unitary body. Another example of how the layers could be connected is by being sewn together, with a stitched seam being positioning along the perimeter of the layers. In this example, the thread serves to connect the layers together. These are just a few examples of how the layers may be connected together and do not preclude the use of other means of connection.

The plurality of three-dimensional pockets 4, the plurality of apertures 5, and the reservoir 21 provide a sealed environment that allows for the containment and displacement of air. The plurality of three-dimensional pockets 4 is positioned on the top layer 1, being adjacently connected above the top layer 1. The plurality of three-dimensional pockets 4 is thus positioned on a side of the top layer 1 that is opposite that of the intermediate layer 3. The plurality of three-dimensional pockets 4 is connected into the top layer 1, with each pocket's 4 interior volume being completely sealed except for a single passage which connects a three-dimensional pocket 4 with the other components of the airflow system. In other words, a hydraulic system allows for pressure-generated circular airflow. Each of the plurality of three-dimensional pockets 4 are preferably deformable, such that when weight is applies from above the three-dimensional pockets 4 will compress, effectively allowing the top layer 1 to act as a cushioned ergonomic surface. The configuration related to the top layer 1 is illustrated in FIG. 1-FIG. 3.

The plurality of apertures 5 is formed by traversing holes through the intermediate layer 3. The apertures 5 allow for the passage of air between the plurality of three-dimensional pockets 4 and the reservoir 21, the latter of which is described in more detail later. As the apertures 5 are provided to allow air to flow out of and back into the three-dimensional pockets 4, an aperture 5 is provided for and aligned with each individual three-dimensional pocket 4. In other words, each specific aperture 5 is aligned with a corresponding three-dimensional pocket 41. The apertures 5 themselves are preferably the size of a pinhole and allow for air passage between layers. The intermediate layer 3 and apertures are shown in FIG. 1 and FIG. 4.

Below the intermediate layer 3, the plurality of apertures 5 provides a passage into the reservoir 21. The reservoir 21 traverses into the bottom layer 2, such that it is positioned interior to the bottom layer 2 adjacent to the intermediate layer 3. The reservoir 21 is closed off at the top by the intermediate layer 3, which effectively seals the reservoir 21 with the plurality of apertures 5 and the plurality of three-dimensional pockets 4. This general configuration results in the three-dimensional pockets 4 and the reservoir 21 being connected with each other through the apertures 5, such that air may flow between the three-dimensional pockets 4 and reservoir 21. These relations are shown in FIG. 1 and FIG. 5.

Since the plurality of three-dimensional pockets 4 is positioned above the top layer 1, there is a need for connecting passages between the plurality of three-dimensional pockets 4 and the apertures 5 of the intermediate layer 3. This is accomplished by providing a plurality of conduits 6, the plurality of conduits 6 creating a sealed passage between the three-dimensional pockets 4 and the apertures 5. The plurality of conduits 6 traverse into through the top layer 1 into the plurality of three-dimensional pockets 4, creating an outlet for air stored in the three-dimensional pockets 4. The ratio of conduits 6 to three-dimensional pockets 4 is 1:1, just as the ratio of apertures 5 to three-dimensional pockets 4 is 1:1. A selected conduit 61 from the plurality of conduits 6 thus cuts a hole through the top layer 1, into a corresponding three-dimensional pocket 41. The selected conduit 61 is also aligned with an aperture 5 in the intermediate layer 3. Essentially, the selected conduit 61 creates a linear passage between one of the plurality of apertures 5 and one of the plurality of three-dimensional pockets 4. Potentially, the passage could be curved (e.g. into a helix shape), or implemented in an otherwise nonlinear form; these are a few non-limiting examples of ways shapes that can be utilized for the passages.

Potentially, the reservoir 21 comprises a first section 22 and a second section 23, though other numbers of reservoirs 21 are possible under the scope of the present invention. In an embodiment where a first section 22 and a second section 23 are used, a channel 25 is formed within the bottom layer 2. This channel 25 traverses into both the first section 22 and the second section 23, allowing air to flow freely between the two reservoirs 21.

As thus far described, the present invention provides an ergonomic support for footwear. The present invention can be placed within a footwear atop an existing insole. When a pressure is applied to the three-dimensional pockets 4 on the top layer 1 (e.g. a person who steps down on the top layer 1 with their foot), the three-dimensional pockets 4 become compressed. The resulting decrease in volume of the three-dimensional pockets 4 increases pressure within each three-dimensional pocket 4. In order to equalize the pressure, the air flows through the conduits 6, the apertures 5 of the intermediate layer 3, and into the reservoir 21 of the bottom layer 2. When the applies pressure is released (e.g. a person lifts their foot away from the top layer 1) the three-dimensional pockets 4 decompress and return to their original size and shape. The resulting increase in volume drops pressures within each of the three-dimensional pockets 4, once again creating a pressure differential. As the area of low pressure is in the three-dimensional pockets 4, air flows from the reservoir 21, back through the apertures 5 of the intermediate layer 3 and the conduits 6, and returns into the three-dimensional pockets 4. Even when stationary (i.e. not changing pressure applied to the top layer 1), the three-dimensional pockets 4 provide a non-rigid surface that improves comfort; this is because a person simply standing will still cause the three-dimensional pockets 4 to compress. Effectively, even when standing the three-dimensional pockets 4 simulate a soft and non-rigid surface that is more comfortable to stand on

To further improve comfort, parts of the present invention may be contoured to better support anatomical parts of the foot. For example, in order to support the medial and lateral arches (both of which are longitudinal arches 26), the bottom layer 2 can comprise an elevated concave portion 24. This elevated concave portion 24 is centrally positioned on the bottom layer 2 in order to align itself with the curvature of the human foot. By matching the longitudinal arches 26 of the human foot, this concave portion 24 allows the present invention to increase the surface area of the invention that contacts a person's foot, providing improved support and more evenly distributing the person's weight across their foot and onto the present invention. Similarly, a first wing 71 and a second wing 72 may be provided to provide side-to-side support. In other words, the first wing 71 and the second wing 72 are adjacently connected to opposite sides of the bottom layer 2, with the elevated concave portion 24 being positioned between them. The first wing 71 and the second wing 72 are contoured to match the transverse arch 73 of a foot. By incorporating either the elevated concave portion 24, the wings, or both, the ergonomics of the present invention can be further improved. These arches and their supporting features are shown in FIG. 5-FIG. 7.

It is noted that the contours of the bottom layer 2 are effectively translated to the intermediate layer 3 and top layer 1, as those layers are pressed atop and connected to the bottom layer 2, resulting in the desired unitary body. Furthermore, the layers are perimetrically aligned with each other, with each layer being congruent with the other layers in order to ensure a smooth connection without jagged edges or other undesirable features.

Components of the present invention can be altered with respect to composition and dimensions without deviating from the scope of the present invention. For example, the size and shape of the plurality of three-dimensional pockets 4 is not limited to bubble shapes, nor do all the three-dimensional pockets 4 need to be provided in the same size and shape. Likewise, the material used for the three-dimensional pocket 4 is not limited to a single type; rather, the chosen material must be capable of containing air within the three-dimensional pocket 4, while also being flexible (e.g. non-rigid), deformable, yet capable of returning to its original shape in the absence of outside forces. The top layer 1, which supports the three-dimensional pockets 4, is ideally manufactured from a durable material. A potential material include plastics such as layered sheets of polyurethane films. The bottom layer 2, as an example, can be made of a durable material such as rubber; this provides a stable base for the wings and the concave portion 24, which is necessary to help properly support the weight of a person's foot.

A further possibility for the present invention is provided a visual graphic printed on the bottom layer 2. In order to provide more flexibility for different sizes of feet and footwear, this printed graphic acts as a “cut line”, allowing the present invention to easily be cut to fit a desired shoe size. In this manner, the present invention can be manufactured for any size footwear, only being cut down to a desired size when ready for distribution to retailers or even directly be an end user. An example of such a visual graphic is provided in FIG. 8, showing dotted lines along which the present invention may be trimmed.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed. 

What is claimed is:
 1. A footwear insole comprises: a top layer; a bottom layer; an intermediate layer; a plurality of three-dimensional pockets; a plurality of apertures; the bottom layer comprises a reservoir; the intermediate layer being connected between the bottom layer and the top layer; the plurality of three-dimensional pockets being adjacently connected to the top layer opposite the intermediate layer; the reservoir traversing into the bottom layer; the reservoir being positioned adjacent to the intermediate layer; and the plurality of three-dimensional pockets being connected with the reservoir through the plurality of apertures, wherein air can move between the plurality of three-dimensional pockets and the reservoir.
 2. The footwear insole as claimed in claim 1 comprises: a plurality of conduits; a selected conduit from the plurality of conduits traversing into a corresponding three-dimensional pocket from the plurality of three-dimensional pockets; the selected conduit traversing into the corresponding three-dimensional pocket through the top layer; each of the plurality of apertures being aligned with the corresponding three-dimensional pocket from the plurality of three-dimensional pockets; and the plurality of three-dimensional pockets being connected with the plurality of apertures through the plurality of conduits, wherein air can move between the plurality of three-dimensional pockets and the plurality of apertures.
 3. The footwear insole as claimed in claim 1 comprises: a channel; the reservoir comprises a first section and a second section; the first section being positioned adjacent to the second section; and the second section being connected with the first section through the channel, wherein air can move between the first section and the second section.
 4. The footwear insole as claimed in claim 1 comprises: the bottom layer comprises an elevated concave portion; and the elevated concave portion being centrally positioned on the bottom layer.
 5. The footwear insole as claimed in claim 4, wherein the elevated concave portion is contoured to match a foot's longitudinal arches.
 6. The footwear insole as claimed in claim 1 comprises: each of the plurality of three-dimensional pockets being deformable.
 7. The footwear insole as claimed in claim 1 comprises: the top layer and the intermediate layer being congruent with the bottom layer.
 8. The footwear insole as claimed in claim 1 comprises: a first wing; a second wing; the first wing and the second wing being adjacently connected to the bottom layer; and the first wing being positioned opposite the second wing across the bottom layer.
 9. The footwear insole as claimed in claim 7, wherein the first wing and the second wing are contoured to match a foot's transverse arch. 